AC compressor drive

[arber333]

Well i have made it.

While i was trying to decypher Leaf AC compressor serial bus or whatever it uses i was getting nowhere. So i decided to just build me a compressor drive.

I will use Volt inverter, so inside is one Aux controler with enough power to drive compressor. It was originaly intended to run Aux hydraulic pump to keep transmission under pressure when car is stationary. When Tom and I inspected this drive we figured it has 50A sensors and while i was putting 10A load onto it it didnt get too warm. https://www.diyelectriccar.com/forums/s ... stcount=84

Now i have one Lebowski board inside inverter connected to AUX drive connector and Leaf compressor on the other side. I must say cables on that compressor are tiny. Just two strands of 0.20mm2 wire. I think max power on compressor is actually 10A.
Look at it running. Noisy boy!

Also Lebowski measured motor parameters... 5100uH and 600mOhm per phase.
Soon i will get Prius compressor and will also try to run it.

Now what i need to develop is a CAN AC controller with some temp sensors and slow RPM ramp logic to simulate throttle ramp up. Also i will only use reset pin only to switch the drive ON. Rest I/Os are not needed it seems.

[arber333]

Well i got Prius gen2 AC compressor here. I love it. It is a simple motor on scroll compressor. It has exterior 3phase cables that one can connect to any inverter. I spent like 5 minutes on Lebowski inverter calibrating motor resistance and inductance. And it ran!

While i think other compressors are more powerfull, this one lends itself better to DIY use.

Prius AC compressor Lebowski parameters:
Motor Inductance: 2550uH
Motor phase resistance: 500mOhm

Voltage used 360Vdc
Current set at 20Arms and max battery current 10A.

[johu]

Nice work
How do match the compressor to the cars existing tubes?

[arber333]

Nice work
How do match the compressor to the cars existing tubes?

Tnx, i will upload video tomorrow

I bought compressor with both tubes. They are alu pipes with flanges. In the middle there is a section of rubber hose. I will do the same as i have done with my power steering hydraulic pump.
I will cut the hose 3/4 from the compressor and take it alu pipe and all to a hardware machinist store where they have propper pliers to crimp hydraulic and pneumatic hoses. If you have sufficient length of rubber hose they can crimp an extention onto that.
I will also take the opposite hoses from the car. They will then make me a fitting to join both sides hoses.

Now it is not that simple as you first think. You have to prepare and measure how much hose you need.
Also you need to be carefull of orientation which hose goes to which port inside cabin. There are some non-return valves there...
I am still thinking of asking them to make me a dissassembly, so i could took the hoses apart if i wanted, but a friend said it is one more point of failure...

[ZooKeeper]

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[arber333]

Those are face-plate seals with o-rings, many places sell make-up ends and hose any length you want, just get the fittings clocked correctly! I have made dozens of hoses with these crimp-on fittings and they work VERY well.

That compressor uses SPECIAL AC oil to reduce the risk of electric transients, mixing with unapproved types can harm the hardware.

Yes the oil needs to be correct.

Can you link or post a pic of the seals and hoses you speak of? You mean you have connected hoses at home?

[ZooKeeper]

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[arber333]

I am a "mechanic" by trade and so have been doing automotive AC work for about 35 years

Found some "compressor adapters": https://coldmasterinc.com/product/sd7b1 ... 0-w-oring/

Kit for crimping the hoses on (actual model I used): https://www.mastercool.com/product/71500/

Very nice thank you. I dont think i can get the like around here. I will search for that stuff. If i find it in EU i will post here.

[arber333]

Bus just made some adjustments to sensorless start alogorithm and AC compressor now starts even easier.

[arber333]

If you want to use AC compressor read here first:
https://www.buyautoparts.com/howto/toyo ... tion-1.htm

And here for the counterbalance
http://www.fixhybrid.com/comp-oil/

[arber333]

I went to search for Toyota 3PH connector from compressor, but i couldnt find any data. Then i tried to find the connector on the side of Volt inverter where i will connect compressor.
It seems like it is YHVA280-3PXM connector and can be get at Mouser. Contacts are 2.8mm AMP MCP female. I may yet pull this off without sacrificing cables and plugs. Datasheet of assembly is attached. It seems to be quite complicated assembly.

I also attach Mouser basket with P/Ns